Proper Order for BOMBing your 3rd Gen

[Vaughn MacKenzie]

In the 5-1/2 years I've been on this board things have changed a lot. It's been fun to see the evolution of these great trucks and the group of owners and enthusiasts that BOMB and drive them.



Back in 1999 BOMBs and upgrade were installed with caution and new territory charted in terms of being able to crank the HP and have the Cummins still live a long life. Ted Jannetty of Jannetty Racing posted a suggested "Proper order of BOMBing" in 1999 which most on the board were familiar with and referred to often. It has mostly been forgotten, and since the Cummins has demonstrated itself to be a mighty durable contender despite major HP BOMBs, I see caution thrown to the wind more than ever before.



Here is the original thread Ted posted: https://www.turbodieselregister.com/forums/showthread.php?t=46675



I would suggest this revised/modernized version, considering stock trucks now come with much more HP, yet the stock turbo is more restrictive than ever (with the wastegate defeated). In principle many follow this already, but I think it's worthwhile to post nonetheless, for those who want BOMBing and longevity:



1) Install a quality set of gauges, exhaust temp at least, boost; trans temp for autos.

2) Install a 4" exhaust from the turbo back (600/610 guys it's up to you whether cat-back or full replacement)

3) Install an aftermarket air intake system with greater flow (and cooler if possible) but say "No" to K&N.

- - The foundation is in place for a mild Box bomb or injectors - -

4) Get rid of that stock turbo

5) Auto guys time to look at transmission upgrades, such as Mag-hytek pan ,VB & TC.

- - You're set for a big box or injectors - -

6) Fuel system upgrades should be next.

- -With these upgrades, BOMBs/power can be increased based on EGTs and what your system can support - -

7) To go higher, time for a clutch or totally built Auto.

- - Now you're set for box stacking, box+injectors, etc- -

8) TWINS if you haven't already



These steps can be skipped or done in a different order of course, they don't apply the same for everyone, but it's a decent rule-of-thumb to go by. And certainly up for debate too . . . those who've been here for several years and have BOMBing experience can chime in



Vaughn

 

[MichaelWright]

That is exactly how I did mine. Never saw Jannetty's list, just used common sense.



Mike

 

[jcarey]

Vaughn, good post. There's a lot of people that can use the info that may not have otherwise found it. I don't know if this information is in the Newbie section ro not, but it should be



MERRY CHRISTMAS, TDR'ers!



Jim

 

[DocDetonancour]

Good post Vaughn! So many posts on these adds it's tough to decide if they help or hurt performance. Thanks, Doc

 

[jsimpson]

TST told me that replacing the stock 03 bexhaust won't get better power or EGT numbers even with their box.

 

[DLeno]

there does seem to be a lack of rigorous work establishing the need for exhaust on the 3rd gens. I sure can't hurt, and probably does help airflow a tad bit. the most important weak spot though, you're right Vaughn, is that turbocharger. not so much for the 600 guys, but for us 555 guys, there is arguably only enough power margin into the mid teens (horspower gain at the rear wheels). lots more discussion on the subject of responsible fueling enhancements and the weaknesses of the stock air systems in TDR issue 47, soon to hit the street.



good post, Vaughn. glad to see responsible bombing still exists.

 

[SRadke]

TST told me that replacing the stock 03 bexhaust won't get better power or EGT numbers even with their box.

I'm not going to argue Mark's findings but I saw a decrease in egt's with a full 4" system.



-Scott

 

[DLeno]

not so much for the 600 guys, but for us 555 guys, there is arguably only enough power margin into the mid teens (horspower gain at the rear wheels).

that was not stated very well. I mean in my opinion, 50-70 horsepower gain is about all there is in the stock charger. without putting long term reliability at risk.

 

[Vaughn MacKenzie]

DLeno I would agree the exhaust system isn't so critical, not so critical as the turbo, but by the time you replace the turbo the exhaust has already been done.



The turbo actually does OK for exhaust-side flow as long as you don't defeat or overpower the wastegate (the wastegate flows well). Force boost past 35psi or so and drive pressure skyrockets (not good for the head gasket and likely not your head either, defeats purpose of intercooling, etc. ).



Compared to older trucks, the exhaust is less restrictive but the turbo more restrictive on the 3rd Gen trucks. The best improvement is to ditch the stock muffler, that's where most of the restriction is. On my '03 I got rid of it and replaced it with a 4" straight through and 4" dia intermediate pipe off a Powerstroke for a budget complete 4" system



Vaughn

 

[Vaughn MacKenzie]

Oh and another thing I shoulda added around step 5-7: get rid of that sorry excuse for an exhaust manifold if you want to keep cylinder #5 alive

 

[Tomeygun]

Gotta love that turbo replacement... Seems the though the stocker is only good as an secondary or a paperweight :-laf

 

[nickleinonen]

i've only done the first 3 steps myself, but not in that order. to me, those first 3 could be put in any order, but they all should be done before moving on to step 4. .

 

[JTeague]

Heres what I have found with the 3rd gen trucks: one 03 305/555 truck + TST box on 9/9 = smoked turbo. One 04. 5 325hp truck + plus TST box on 9/9 = totally destroyed turbo. One 05 325hp truck + TST on 9/9 = noisey turbo. Do you see the trend here? Anyone who thinks that the stock turbo will survive with a TST box or a similar box turned on kill is crazy. All 3 trucks experienced turbo failure with only just a couple of seconds of running on the high setting. The older HX-35 equipped trucks may have gotten nuclear hot after a short period of hot rodding with serious fueling, but at least they held together. These new turbos won't withstand hardly anything without going BANG. A bigger turbo should be at least #3 on the 3rd Gen BOMB list IMHO.

 

[DLeno]

see TDR 47 where Joe and I discuss the limits of the stock turbocharger in some detail. There is little point is taking this component above 65 horsepower over stock. thats for the 555's at least. there may be more margin in the 600 turbo I don't know.

 

[Talltimber]

I would have to disagree with TST in not installing intake and exhaust along with their box. As we all know the internal combustion engine is just a big air compressor. It sucks air into a confined space, adds a shot of fuel and a heat source, to create an explosion. Once the explosion has occured it gets rid of the off-gass. It stands to reason that If you add more fuel without adding the enough oxygen to utilize the additional fuel it will not be as efficent as it would be by adding the ability to move more oxygen in and exhaust more off-gass's. just my . 02 worth

 

[Tomeygun]

I would have to disagree with TST in not installing intake and exhaust along with their box. As we all know the internal combustion engine is just a big air compressor. It sucks air into a confined space, adds a shot of fuel and a heat source, to create an explosion. Once the explosion has occured it gets rid of the off-gass. It stands to reason that If you add more fuel without adding the enough oxygen to utilize the additional fuel it will not be as efficent as it would be by adding the ability to move more oxygen in and exhaust more off-gass's. just my . 02 worth

The only thing I can think of, Is when TST is saying they have found nothing to cool egts, I think they mean nothing to cool EGTs with the box on 9/9 to a safe level



Because I know I dropped egts with both my open exhaust and my AFE... but the higher settings will still peg a gauge on the street

 

[nickleinonen]

A bigger turbo should be at least #3 on the 3rd Gen BOMB list IMHO.

i really don't think so. the gauges/intake/exhaust should be first...



with the tst set at 9/9, i don't think that conforms to the bullit between item 3 and item 4 in the list

3) Install an aftermarket air intake system with greater flow (and cooler if possible) but say "No" to K&N.

- - The foundation is in place for a mild Box bomb or injectors - -

4) Get rid of that stock turbo