How To: Build your own 4.0L turbo Cummins (Beware...170+ pics)

merdock69 said:
Boostwerks, did you end up not going back with the copper RTV and anerobic flange sealer when you re-assembled? I notice in these new pictures you have a metal plate gasket. If you did switch, I'm curious why and what you went with this last time.

Thanks,
Click to expand...

Since I switched to the later casting I decided to use the MLS manifold gasket, which as I understand is the OEM gasket used on the late models. The MLS has indentations to maintain a compression seal around the ports. I did still use a very light coating of the RTV and anerobic goop on the manifold side however to ensure a leak free seal.
 
Did you ever get this on the dyno?
What is your IAT as read by OBD scanner at wot and at what boost?
Thanks
 
CobraMarty said:
Did you ever get this on the dyno?
What is your IAT as read by OBD scanner at wot and at what boost?
Thanks
Click to expand...

Sorry about the late replies, but we havn't dyno'd yet. The AW4 like many others have witnessed, has been our biggest limitation. We do have a replacement coming however, and will dyno as soon as we can.

We have logged IAT's from 100 up to 140 this last summer (100deg ambient).

Are the studs at each end of the manifold (the one that sheared) is it the same size as the ones in the middle?

Thanks
Click to expand...

The end studs are the same as the centers. :thumbup:
 
Boostwerks.com said:
Sorry about the late replies, but we havn't dyno'd yet. The AW4 like many others have witnessed, has been our biggest limitation. We do have a replacement coming however, and will dyno as soon as we can.
Click to expand...
Our problem with trying to dyno the AW4 was keeping it from downshifting or upshifting gears. I am going to use a modified RADesign shifting where I will switch on solenoids #1 and #2 to keep it in 2nd gear and switch on solenoid #3 to lock the torque converter on and then do a dyno pull from 1500-5000rpm.
Boostwerks.com said:
We have logged IAT's from 100 up to 140 this last summer (100deg ambient).
Click to expand...
Those are great IATemps. Gotta love intercooling.
 
CobraMarty said:
Our problem with trying to dyno the AW4 was keeping it from downshifting or upshifting gears. I am going to use a modified RADesign shifting where I will switch on solenoids #1 and #2 to keep it in 2nd gear and switch on solenoid #3 to lock the torque converter on and then do a dyno pull from 1500-5000rpm.

Those are great IATemps. Gotta love intercooling.
Click to expand...

Yeah we will more than likely end up having to do the same. Yeah, the IC works great. I do still need to add an expansion tank however.

And since it's been a while, here's a bunch of random poser shots just for fun...:thumbup::wierd:

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1009.jpg


1006.jpg


310760_1893921881721_1651793354_1524033_38752291_n.jpg


2012-06-19130300.jpg


2012-06-19130105.jpg


2012-06-19130045.jpg


2012-06-19125820.jpg


2012-11-03190527.jpg
 
One thing I would have suggested is a turbo cover to keep heat away from wires and such, but wow...I'm impressed. I wonder what kind of mileage you're getting...
 
cdrake261 said:
One thing I would have suggested is a turbo cover to keep heat away from wires and such, but wow...I'm impressed. I wonder what kind of mileage you're getting...
Click to expand...

I do have a turbine blanket...

1027.jpg


Thank you though! It does not fair well in terms of mileage. I avg roughly 18mpg combined 50/50 highway/city. I'm sure it would be much better with a manual trans however.
 
Seriously, I just read 23 pages and no dyno results! Almost 3 years of junk and no numbers?! I was seriously considering this at first, but I'm shooting for 450-500whp and I'm not convinced you can make that. It might be better than the 190hp that it is rated for, but I don't think this is the route I will take.
 
sandyeggoxj said:
Seriously, I just read 23 pages and no dyno results! Almost 3 years of junk and no numbers?! I was seriously considering this at first, but I'm shooting for 450-500whp and I'm not convinced you can make that. It might be better than the 190hp that it is rated for, but I don't think this is the route I will take.
Click to expand...

450-500 whp is a lot to ask from a 4.0L even with a turbo. What other mods do you have planed?

Our turbo setup is kinda similar to Boostwerks except his is a much higher quality. If you want some numbers to compare to at about 6 psi from a 50 trim T3/T4 with intake temps around 140 degrees our makes 201 whp/ 263 wtq. I’m guessing his will be closer to 215hp/275tq.
 
I was actually leaning toward an ls6 type motor. Out of the crate @ 400hp on the crank. Easy to tune/bolt-on stuff and big aftermarket scene. haven't settled on a transmission but needs to be at least 5-speed, ideally 6-speed.

I know that a na 350+hp stroker can be put together. Maybe boosted to push up into the 400's. I don't know. Planning for maybe later this year or next year for the powertrain swap.
 
ummmm... so you aren't going to consider Boostwerks setup because no numbers, not because it's for a 4.0 not an LS6?

I'm not sure of the logic here.

:huh:
 
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