On this episode of HOT ROD Garage
Category
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MotorTranscript
00:00 (rock music)
00:02 - Welcome back to Hot Rod Garage presented by Lincoln Tech.
00:22 In this episode, we're gonna take our 1973 Dodge D200
00:26 12 valve Cummins swap that we have started calling
00:28 Roll Smoky, and I'm gonna double the horsepower
00:31 and torque on this thing with just a few basic modifications.
00:34 But first, get out your pens and pencils
00:36 and your laptops and your notebooks,
00:38 'cause Clarence Barnes is gonna take you to school
00:40 with this quick tech tip from Lincoln Tech.
00:42 (upbeat music)
00:45 Ever see fish eyes in a custom paint job?
00:47 They're those small circles that give the surface
00:49 a rough, wet look after the paint has dried.
00:51 Fish eyes are caused by a reaction between the paint
00:54 and a surface contaminant during the painting process.
00:57 The most common contaminant is silicone,
00:59 but oils from your hands and even detailing products
01:02 that inadvertently land on the body prior to painting
01:05 can cause the dreaded fish eye.
01:07 The only surefire way not to go fishing
01:09 with your next paint job is to be absolutely sure
01:12 that everything you bring into the shop
01:15 is free of silicone.
01:16 You also need to clean the body panels thoroughly
01:19 with a solvent-based wax and grease remover.
01:23 If you do get fish eyes, you're screwed.
01:26 The only remedy is to clean the panel again
01:28 with wax and grease remover, sand it down,
01:30 and fire up your spray gun again.
01:33 Lincoln Tech can teach you how to have a career
01:35 working with cars.
01:36 See lincolntech.edu.
01:38 So we've got my good buddy Brendan Jones here
01:40 helping us today.
01:41 One of the last things we did at my shop in Philadelphia
01:43 is we took Brendan's '78 Ford Super Cab truck,
01:46 we dropped it onto a '97 Dodge 3500 diesel frame.
01:49 That sort of started my love affair
01:50 with these 12-valve Cummins motors.
01:53 But like I said, today we're gonna double the horsepower
01:55 and torque of this thing, and it only takes a few upgrades.
01:57 We're gonna do a turbocharger, an exhaust manifold,
01:59 injectors, and then we're gonna do some fueling upgrades too.
02:03 And all that is gonna take this thing
02:04 from 160 to 320 horsepower,
02:07 and from 400 to 800 foot-pounds of torque.
02:10 First thing we're gonna do is yank this turbocharger out.
02:12 You ready?
02:12 - Yeah. - Cool, let's go.
02:14 So after 180,000 miles,
02:17 our stock turbocharger has seen better days.
02:20 So we're gonna upgrade this thing.
02:21 Now my buddies at Lemon Engineering
02:23 put together this Garrett GTX3582 ball-bearing turbo for us.
02:28 They actually found
02:29 that a Buick Grand National exhaust housing
02:31 is just about the right size,
02:32 and it's internally waste-gated,
02:33 so it's gonna work perfectly for this application.
02:36 With the stock turbo off,
02:41 we are able to yank off the stock exhaust manifold,
02:44 and I'm gonna replace it with this.
02:46 This is a three-piece cast high-flow manifold
02:48 from Diesel Performance.
02:49 Stock manifolds shrink over time when they crack.
02:52 The fact that this is three-piece
02:53 is gonna make sure that doesn't happen.
02:55 It's higher-flowing than stock,
02:56 and it has a couple of bungs here, that 4EGT probe,
02:59 so it's a really nice piece.
03:01 All right, I'm gonna cut the original V-band
03:12 off of this exhaust and weld on a bigger V-band
03:14 that works as our turbocharger,
03:15 while Brennan gets started
03:16 on the first of our fuel modifications,
03:18 which are these plus-40 horsepower injectors from BD Diesel.
03:21 There you go, Brennan.
03:22 All right, so we're gonna pull off this valve cover
03:31 and this intake manifold
03:32 and get these injector lines off of here,
03:34 so we can get at the injectors
03:35 and the delivery valves in the injection pump.
03:38 Yeah, what in the (beep) is it?
03:42 Oh, I think it's important.
03:43 Nah.
03:44 All right, so while Brennan finishes up
03:45 the injector install,
03:47 I'm gonna dig into this P-Pump,
03:48 or the P7100 Bosch high-pressure fuel pump,
03:51 and install the first of a couple modifications.
03:53 The first one is a fuel plate.
03:55 As I understand it, and I'm not 100% sure,
03:58 under full throttle and as boost builds,
04:00 this controls the curve of the fuel delivery.
04:05 It's stock fuel plate versus a number 10 fuel plate.
04:09 See, this one kinda looks like a ski jump over here,
04:11 and this one, sorta like a guy wearing a hat.
04:13 Obviously, a ski jump is gonna beat out
04:15 a guy wearing a hat every day.
04:17 Here's the thing, we're not exactly sure
04:19 (laughing)
04:20 how all this (beep) works.
04:22 I just don't know.
04:23 - We'll figure that as we go along.
04:25 - After some research, turns out the fuel plate
04:27 controls the amount of fuel delivered to the engine
04:29 as RPM increases.
04:30 - And that's it, move the shutoff arm, blah, blah, blah.
04:35 - And I had my buddy Rob Parsons
04:36 weld this aluminum 90 onto the compressor housing.
04:38 You should check him out.
04:39 His car is on the cover of Super Street this month.
04:41 It's red.
04:42 Let's get this on and get the turbo bolted in.
04:44 There we go.
04:46 (upbeat music)
04:49 The last thing we have to do on this turbocharger
04:55 is install the oil feed line.
04:57 You're gonna run a ball bearing turbo like this.
04:58 You wanna get an oil feed restrictor.
05:01 They have these cool fittings
05:02 with restrictors integrated in them
05:03 because they need restricted oil flow,
05:05 or they will smoke out the exhaust.
05:08 So let's put this in.
05:09 (upbeat music)
05:10 You don't put a restrictor in.
05:11 This thing's gonna smoke more
05:13 than your douchebag vaping cousin.
05:15 Nobody wants that.
05:17 (upbeat music)
05:19 I think it's cool.
05:21 It's not cool.
05:22 After plumbing the turbo to button up the engine bay,
05:24 we had to make a hybrid high pressure line
05:27 using the fittings from the D200 steering gearbox
05:29 and flaring it onto the Cummins power steering line.
05:32 For cooling, we used a radiator and hoses
05:35 out of a '93 Cummins Ram.
05:37 We welded a plate into our rad support
05:39 and made bolt-in upper mounts.
05:40 We used the stock intercooler from the '95 Ram 200.
05:43 It's got great flow and it's thin enough
05:45 to fit behind the D200 grill.
05:47 We mounted it by welding the '95 mounts
05:49 into the 1973 rad support.
05:52 To make the intercooler piping work,
05:53 we wound up cutting three inches
05:54 out of the stock intercooler piping on the cold side.
05:57 And it looks like if we weld that three inches
05:58 right back into the hot side,
06:00 that side's gonna work great too.
06:01 So this thing was meant to be.
06:03 Ha ha, all right.
06:04 (upbeat music)
06:12 So I found this cool four inch aluminized exhaust online
06:15 for like 300 bucks.
06:16 And you saw before I welded the proper V band
06:18 and made up to our new turbo on there.
06:20 I think it's gonna fit the truck really well.
06:22 I bought it for a '93 Ram 250 with a Cummins in it.
06:25 I don't wanna use the whole thing.
06:26 I'm gonna just jam it outside the truck
06:28 in front of the rear wheel,
06:29 make a lot of smoke and noise, should be cool.
06:32 That part fits great.
06:36 Super easy by yourself.
06:38 (upbeat music)
06:42 (metal clanking)
06:45 Now that we've got the engine and turbo all squared away,
06:52 we can turn our attention to this 47 RH transmission.
06:55 Now stock, this thing would have never held up
06:57 to the kind of horsepower and torque we're trying to make.
06:59 But luckily, BD Diesel outfitted us
07:01 with a full upgrade package.
07:03 So that package included an upgraded torque converter,
07:06 a larger pan, a stage four rebuild kit
07:09 with extra clutches in there,
07:11 and a valve body that they modify for more performance.
07:13 Now to be able to shift the 47 RH in our '73 D200,
07:17 I used a combination of 727 parts and 47 RH parts.
07:20 I pulled the shift selector right off that 727
07:23 and bolts right onto this 47 RH,
07:25 as well as the shift pivot mount.
07:28 With that stuff in place,
07:28 I just had to extend the shift linkage coming off the column
07:31 and it should work great.
07:32 (upbeat music)
07:35 (metal clanking)
07:37 Maybe.
07:48 All right, so the transmission went in really easily,
07:50 really straightforward.
07:51 I was a little worried about the transmission tunnel
07:53 clearance for those top two bolts,
07:55 because we have it jammed in there pretty tight,
07:57 but they weren't too bad to get to.
07:59 Now what we've got left is to bolt the torque converter
08:00 to the flex plate, install the drive shaft,
08:03 and fab up an exhaust.
08:04 This thing should be just about ready to drive.
08:06 (upbeat music)
08:09 All right, we've got it all back together.
08:30 I've got the alternator
08:31 and the fuel shutoff solenoid wired up.
08:33 Once we prime the fuel,
08:34 this thing should fire up and be awesome.
08:37 We drained all the fuel out
08:39 and you gotta like manually prime it,
08:41 'cause it's a diesel.
08:42 Gonna prime it a couple more times.
08:44 He's single, ladies.
08:46 (upbeat music)
08:50 (man whooping)
09:01 All right, we've got Roll Smokey all back together.
09:03 We threw the fenders, the hood, the front bumper.
09:06 I cut the grill out to fit.
09:07 We put a fresh black coat of paint on this intercooler.
09:10 I almost don't wanna put that grill back on
09:11 because this looks super tough.
09:13 All right, we're gonna break this thing in
09:15 and head right to the dyno.
09:16 (upbeat music)
09:19 (engine revving)
09:21 All right, we just got to West Tech.
09:43 These guys were nice enough to stay open for us
09:45 'cause it took us like two hours in traffic to get here,
09:47 which was a nice transmission break-in
09:49 for Roll Smokey here.
09:50 In as driven over form,
09:52 meaning we haven't turned the boost up,
09:54 we haven't played with the fuel screws, any of that stuff.
09:57 It's doing 290 horsepower and 730 foot torque at the wheel.
10:02 So we are already super close to our goal
10:04 because like I said,
10:05 these things respond crazy to modifications.
10:08 This thing is a beast already
10:10 and we are gonna make 320, 800.
10:14 That's gonna happen.
10:15 All right, we're gonna try again.
10:16 (upbeat music)
10:19 EGTs are really low.
10:24 So I'm gonna pull some fuel out of it,
10:26 sliding that AFC plate back towards the firewall
10:29 and we'll see if it comes up,
10:30 gives us a couple more pounds of boost
10:32 and hopefully gets us where we need to be
10:34 for those dyno numbers.
10:35 (upbeat music)
10:38 (engine revving)
10:46 (tires screeching)
10:49 All right, on that last dyno run,
10:53 this thing put down 293 horsepower
10:56 and 755 foot pounds of torque at the tire.
10:59 So if you factor in driveline losses,
11:01 that puts us right at double the horsepower
11:04 and torque of the stock engine.
11:05 That's a win.
11:07 So that's it for our time with Roll Smokey over here.
11:10 In two episodes, we dragged that junk truck out,
11:14 took the engine out of it, took the engine out of this,
11:16 made mounts, made a transmission mount,
11:17 drive shaft, intercooler, radiator.
11:19 And then on top of that, we rebuilt the transmission.
11:22 We did big injectors, big turbo and a fuel plate.
11:25 So we made this thing run and double the stock power.
11:28 It was a lot of work,
11:29 but I'm really glad we got into it
11:30 because this truck is awesome.
11:31 It rules.
11:32 It's mine.
11:33 I love it.
11:34 It makes 300 horsepower at the tires
11:36 and almost 800 foot pounds of torque.
11:38 I can't wait to mob all over LA in this thing.
11:41 This truck rules.
11:42 This was a good episode.
11:43 That's it for this episode of "How to Hire a Garage"
11:45 presented by Lincoln Tech.
11:46 Check us out on Facebook at Hot Rod Garage Show.
11:48 Check me out on Instagram, tangelo96
11:50 and check out #rollsmokey.
11:52 (rock music)
11:55 (rock music)
11:57 (rock music)
11:59 (rock music)
12:02 Bam!