Great Lakes 4x4. The largest offroad forum in the Midwest banner
41 - 60 of 70 Posts

· Registered
Joined
·
99 Posts
Discussion Starter · #45 ·
Got all the coolant bypass lines done, intake manifold, rest of the tubes made over the weekend, and vw ecu fit in the ford ecu box. Had to mill 3/16" off each side of the ecu case, but it fits now.





Got the dp all done, 3" fit perfectly! Going to feel a little bad covering this with heat wrap.




Midpipe tucked up like a glove
 

· Registered
Joined
·
99 Posts
Discussion Starter · #49 ·
Have 500 miles in the truck so far! Boost is currently 38psi total, 20psi on low pressure stage. Trying to find a high hz solenoid that will work with vw ecu so I can get boost up to 50-55psi. Towing a bmw 135i on my 20' aluminum car hauler was perfect; 950-1150° egt's and 25-35psi of boost depending on grade in 4th gear at 65mph and 2800rpm.

Since this guy is 100% rust free, I wanted to keep it that way so a whole gallon of fluid film went on the underside and basically everywhere salt spray would hit.


I took the truck on a 6 hour round trip on Monday and it started running funny on the way back. Didn't hear any funny noises so I figured an injector solenoid just took a crap. Upon inspection, I wish it was only the solenoid. In 10 years of professionally working on euro diesels, this is a new one on me.


I was planning on upgrading injectors eventually, but certainly not this quickly. I just finished installing a set of 20% over injectors so we'll see how it runs now with a little more fuel! Just waiting on my tuner to email me an updated file to flash in.
 

· Registered
Joined
·
99 Posts
Discussion Starter · #54 ·
Looks like it scoots along nicely. How's the fuel mileage? Empty you've got to be pulling down some pretty solid numbers?

Cool project.
It definitely moves infinitely better than the 3.0L pos that was in there before. So far the worst mpg has been 21. I haven't been remotely trying to conserve fuel and somewhere in 22-25mpg range seems to be the norm so far. 32" load range e tires, a moderately tall truck, wot datalogging, lots forest road cruising, and a heavy foot don't make for the best mileage :sonicjay:. I just ordered a winch bumper last night so that won't help mpg either probably. But the truck needs a winch and for $400 shipped I can't build a bumper myself.
 

· Gustafson
Joined
·
10,843 Posts
It definitely moves infinitely better than the 3.0L pos that was in there before. So far the worst mpg has been 21. I haven't been remotely trying to conserve fuel and somewhere in 22-25mpg range seems to be the norm so far. 32" load range e tires, a moderately tall truck, wot datalogging, lots forest road cruising, and a heavy foot don't make for the best mileage :sonicjay:. I just ordered a winch bumper last night so that won't help mpg either probably. But the truck needs a winch and for $400 shipped I can't build a bumper myself.
I don't know what these put down stock, but with your mods, any guess what your HP / TQ numbers are?
 

· circling the drain
Joined
·
35,865 Posts
It definitely moves infinitely better than the 3.0L pos that was in there before. So far the worst mpg has been 21. I haven't been remotely trying to conserve fuel and somewhere in 22-25mpg range seems to be the norm so far. 32" load range e tires, a moderately tall truck, wot datalogging, lots forest road cruising, and a heavy foot don't make for the best mileage :sonicjay:. I just ordered a winch bumper last night so that won't help mpg either probably. But the truck needs a winch and for $400 shipped I can't build a bumper myself.
Well, with taller, heavier tires, no attempts to get better mileage, etc. Sounds pretty solid to me. Most of those trucks seemed to hover around 17-18 at best stock. Plus now you have a ton more power.
 

· Registered
Joined
·
99 Posts
Discussion Starter · #58 ·
I don't know what these put down stock, but with your mods, any guess what your HP / TQ numbers are?
This tdi was stock 134/235 and I should be about 225/425. I know I can slip the clutch that's rated for 435tq below 2200rpm if I try in 4th or 5th :sonicjay:.

Well, with taller, heavier tires, no attempts to get better mileage, etc. Sounds pretty solid to me. Most of those trucks seemed to hover around 17-18 at best stock. Plus now you have a ton more power.
My truck averaged 14mpg with the 3.0L and had NO balls. So i'm ecstatic to have ~10mpg better and actually have some nuts.
 

· Gustafson
Joined
·
10,843 Posts
This tdi was stock 134/235 and I should be about 225/425. I know I can slip the clutch that's rated for 435tq below 2200rpm if I try in 4th or 5th :sonicjay:.

My truck averaged 14mpg with the 3.0L and had NO balls. So i'm ecstatic to have ~10mpg better and actually have some nuts.
:rock: that's impressive!
 

· Registered
Joined
·
99 Posts
Discussion Starter · #60 · (Edited)
As much as I hate to buy fabricated things from other places, I picked up a bumper from Affordable Offroad. For $430 to my door, there's no way I could've built it for that. As a professional fabricator, the weld and build quality is well above and beyond my expectations. I have much more pressing ways to spend 2 days of welding/grinding time at my shop currently.

Coat of zinc primer done, toss on some black rustoleum in the morning.
 
41 - 60 of 70 Posts
Top