Fummins Build - Part 4

There has been a lot of progress in the last few days!  The engine officially runs, and sounds great! A little loud with just the hot-pipe coming off the turbo, but sounded smoooooooooooth!  After the P-Pump and lines were bled and all air was gone, it fired right up every time.  These P-Pumps start FAST.

The ATS 47RE was built and finished as well!  This  transmission features our standalone SelectShift valve body and controller. This transmission is now programmable to drive however I want it.  It allows for adjustable shift points, converter lock-up, line pressure, and just about anything else you can control in the transmission. It also features an ATS billet flex plate, billet input shaft, and ATS Five Star Torque Converter.  All this combines to hold up to 650hp.  Billet output and intermediate shafts are required after that power level.  But 650hp is plenty for this thing.

It only took an hour or two to install the transmission due to all the room under the Ford body.  That was a VERY welcome change actually having room to work!  I re-used the stock Ford transmission crossmember, and I only needed to drill one hole.  It lined right up!  We will see if I even have to change the driveshafts at all.  I have a feeling that I wont. Next, I have to change the head gear in the transfer case to mate up to the dodge transmission. Dodge and Ford actually share the same transfer case, so all it takes is a change in head gear and they bolt up. I also have to make linkage brackets and transmission cooler lines.  But that probably wont be all that difficult.  

I also made a bottom turbo mount.  It looks like it should fit...but holy close call batman!!!  The S475 BARELY fits in there.  There is hardly any room on either side, I have a feeling that the turbo is going to run into the heater box when under full load, but hopefully a little trimming will free up some room.  I think a heat blanket is in order for both turbos being so close to the plastic parts on the heater box.  I also plan on using a common rail drain tube to return the oil into the pan,  that should keep things simple and factory fit.

There are still some things to do, but its actually not all that much.  All there is left to do is finish up the boost tubes, make a bottom coolant hose to the radiator, and finish putting the front end together, and the truck will hopefully be good to go! Stay tuned to find out!

Single Turbo 6.4 - Project 6.4ANNA

It has begun!  ATS has started on turning a Plain Jane Ford 6.4 powerstroke, into a single turbo, twin K16, tire burning powerhouse!  The truck will recieve the following treatment:

• SINGLE AURORA 5500 TURBO SYSTEM-ATS DESIGNED
• TWIN K16 FUEL SYSTEM-ATS DESIGNED
• ATS BUILT 5R-110W
• HEAD STUDS
• 200 HP INJECTORS
• AIR DOG FUEL PUMP

The truck is slated for an all out performance build to test the 6.4 platform and see what it can handle.  The Aurora 5500 is a 74mm turbocharger that is capable of over 900RWHP as a single turbocharger and designed for streetable spool up and massive power.  The single K-16 fuel system is good, but no where near enough fuel to keep up with the added airflow, and thus we opted to develop a twin K-16 fuel system.  With the addition of another High Pressure Fuel Pump, the system is capable of 4 digit horsepower, and the ability to feed the massive 200HP injectors.  Both pumps will be fed by an Air Dog Fuel pump to supply positive pressure from the tank, to the inlets of the K-16's.

The first order of business is to make sure the head is not going to lift under high horsepower, so we are lifting the cab to install ATS head studs.  These will ensure that the head gaskets do not blowout when the turbo is supplying full boost to the cylinders.  Head studs are generally required anytime over 45 psi of boost is made to maintain reliable horsepower.  The 200HP injectors are also being installed at the same time.

Next, we turned to the factory turbos.  They were removed to make way for the new Aurora 5500. For mock up purposes we used a similar sized T-3 housing.  A mount was made where the factory turbos used to be, and the single turbo was installed.  It fit like it was from the factory!  Also, the turbo will be waste gated, and excess exhaust will be routed into the down-pipe.  With the waste gate, boost and drive pressure should be able to achieve 1:1, which is ideal for peak performance, low EGTs, and maximum efficiency.

Fummins Build - Part 3

The motor is officially in the truck, sitting level, and everything clears...EVEN THE AURORA 3000 sitting on top of the 3-piece manifold.  All the wiring was converted over to hook up to the Cummins.  It only takes about an hour to hook everything up...these P-Pumps are so dang simple!

It was definitley a tight fight getting the oil pan over the front cross-member and the valve cover under the cowl, but with a little finesse and a little persuasion, it goes in.  Then after some wiggling to get it to sit straight, it was bolted down.  The motor actually seems to fit relatively well, and there is a lot of room on either side of the engine to work on.  The throttle cable took a little modification, but now almost looks like it was factory.

All the wires were hidden and wrapped in wire loom (Except for a few that needed to be modified so I left them un-wrapped.  Also, while the engine was out, the frame was painted with 3M rubberized under-coating. After the years of Colorado roads...it needed some love too.

The Aurora 3000 fits perfectly, and has plenty of room for heat dissipation as well.  There is even room for the S475 that is going to be mounted below as well.  Next, I will be filling it up with oil, priming the system, set the P-Pump timing, and fire it up.  Hearing that motor run will be super sweet!

Fummins Build - Post 2

  

Finally got the motor put back together and ready to run. The new cam and valve train were reassembled, torqued, and valve clearance was set.  So now after I set the pump timing, put some oil in it and hook everything up, it will be time to fire it up!

Fummins Build

Here we are at the start of rebuilding a 24 Valve into a P-Pumped, twin-turbo cruiser/camper/worker/beater/fun truck (its got a lot to accomplish).

The truck started out as you see it, with a V-10 with a great sounding rod knock. I took care of that one morning by starting it up cold and throwing the fuel at it.  After creating a new "Crank Inspection Hole", I started to pull the "lightweight" V-10 out, to make way for the P-Pumped 24 Valve.

First thing was to tear it down and make sure everything was looking good.  While I was in there, I decided to replace the bearings, tappets, and add a performance cam. As well as some of the major gaskets and seals of course.

Our machine shop did a little bit of freshing up on the head, because some of the valves were slightly leaking. So in order to make them seal up properly, some of the valves were ground down, and re-seated.  And a through cleaning and valve seals were replaced.  A new head gasket went in, and the ATS headstuds were torqued down to 130 ft/lbs, in preperation for the compounds going on.

With everything sitting right and shiny new, I started the P-Pump conversion with a little baby 160hp P-Pump and schied diesel injection lines.  Injectors were sent of to have the pop-pressure set to 280 BAR to compensate for the P-Pump pressure, instead of the VP pop-pressure.  The Ford V-10 Alternator was also kept for a simple plug and play app.  Just had to fabricate some brackets to hold it.  Destroked was used for the motor mounts.  A the factory dodge adapter plate and starter were kept, in anticipation for an ATS trans with standalone valve body, billet input shaft and billet flex plate.  A custom power steering line was also made.

And here is what we are working with.  2000 Ford F-250 on 38's code name Turd Burgler.  Not pretty, but is gonna be a fun ride!

New Tricks For An Old Dog - Compound Turbos 4.0

[Guest Post by: Chris Burandt]

Fabrication and mounting underway for the Aurora Compounds

I was really hoping I was going to have to cut a hole in my hood to fit the compounds.  That way everyone could see how cool and clean the big Aurora 7500 looks like sitting in there.  To my disappointment everything fits and the hood closes properly...bummer :)  It's so sweet how clean this kit is.
I know it's not possible but it almost seems like there is more room under the hood with the extra charger in there.  Really seemed to open things up after they moved a couple things around.  I traded in my boost gauge that only read 35 psi for a 60 psi gauge.  Almost brought a tear to my eye thinking about 50 lbs of boost!
Applied Plastic Coatings received the Fusion Bumpers which will house the LED lighting and began adding the nylon coating in white to match the truck's paint. More pictures to come and we're getting close!

Piping is fabricated for the compound turbo charge pipes	Applied Plastics coats the Fusion Bumpers white
The Aurora Compound Turbo System as seen through the fender well	Chris mounts part of the now coated Aurora Turbo System

New Tricks For An Old Dog - Engine Mods 3.0

[Guest Post by: Chris Burandt]

Now we're talking!  Motor got put back into the truck with a fresh head gasket, ARP head studs and a sweet looking set of ATS manifolds and up-pipes.  Now the fun begins.  Over the next couple days the plan is to get the compound turbo kit installed.  For turbo's, ATS is going to be using the stock charger with their Aurora 7500 which will create awesome response on the bottom and tons of air up top to fix my high exhaust gas temperature (EGT) problem.  It was so frustrating to me with my previous set up that I had tons of power but no way to use it when pulling up the passes because of excessive EGT's.

With the lack of air we have up here in the Colorado high country I'm so excited about compounds!  All this talk of not being able to get a truck with compounds over 1200 degrees has got me smiling.  I've seen 2000 degrees on my current set up!!!  YIKES.  Bring on the air!!

Chris at ATS mounted up the Twin CP3 kit.  After talking with Clint Cannon, the owner of ATS, I really like what the twin CP3 kit brings to the table.  Even though we're going to be running stock injectors for this towing set up the extra fuel provided by the twin CP3 kit not only maintains desired rail pressure at all times but it also makes the truck run way smoother.  What I also like about this kit is it allows me the option to go bigger in the future with my injectors or a more aggressive EFI live tune as well.  Oh and that billet pulley that drives the second pump looks way cool too!

 

My wife actually told me I was pathetic when after I signed the papers on this truck. I only made it the 17 miles from the dealership to ATS's shop to get the first modification done.  I originally bought this white beauty with 80,000 miles on it and I new 2 things as soon as I drove it off the lot; One was that I couldn't leave it stock, and two was this poor truck would have a trailer behind it 75% of the time.  So it was a no-brainer to me to have the boys at ATS throw in one of their big bad purple transmissions with a Five Star Torque Converter and Co-pilot to handle any load or amount of power I could throw at this thing.  To date it has been the best modification I have ever done to the truck.  It's funny when I get in another diesel and drive it around, especially a modded one that doesn't have any tranny work, how much more solid mine feels than the stock ones.  What a difference!

Can't wait to see the compound turbos next!

New Tricks For An Old Dog - Lift and Suspension Mods 2.0

[Guest Post by: Chris Burandt]

And so it’s begun!   The boys at ATS are elbows-deep into turning my once stock riding, grandpa-looking, super clean dually into a compound (twin) turbo breathing, Cognito-lifted pull-any-trailer-way-too-fast, beast of a truck!  With 170,000 miles on the ol’ girl we decided to do the head gasket, add some head studs and check the injectors.  Come to find out the head gasket showed some signs of leakage and there was one injector out of spec.
 
I’m really glad ATS leaned me towards going through the motor.  It would have been a bummer to put all the goodies on and then have to tear it back apart later down the road.  With a new head gasket and injector this bad boy 6.6L will be good for another 170,000! 

Phase 2, the lift.  When the tech got the Sawzall out I thought he was just joking around with me.  Then the safety glasses came on…real funny guys.  Then I had to jump out of the way so I didn’t lose an arm!  I could tell this wasn’t Chris’ first rodeo with Chevy suspension installs.  After weeks of research on the internet it was clear the only way to go up with the dualler was a lift from Cognito Motorsports.  Cognito’s patented products, insanely good fit and finish, and the ability to retain stock drive angles made this purchase a no brainer.  For all the towing this truck will be doing with 5^th wheel and goose neck trailers I decided to go with the 4-6 inch lift.  I was able to get my low rider off the ground, but nothing too crazy to affect the great towing characteristics of the truck.  I can’t wait to see what this thing looks like when it hits the ground!

This is truly one heavy duty lift.  I’ve had lifts installed on several other vehicles in the past but nothing as overbuilt with OEM like fitment as this Cognito kit.  I haven’t even seen the truck on the ground yet and I’m pumped!

Like a kid on Christmas I couldn’t get the Fox RacingShox box open quick enough.  I run Fox Shox on all my snowmobiles so again running these bad boys on my truck was an easy choice.  I went with remote reservoir shocks front and rear.  Pictures don’t do these things justice.  Between the burly looking Cognito kit and the trophy truck like Fox shox this really is going to feel like a brand new truck.  As you can tell by the aggressive tread pattern I like to run on my 215s I can’t wait to throw some new meats on.  Is there anything better than new tires? OK, enough torture, can we please quit taking pictures and put this thing on the ground!  I wanna see it! 

New Tricks For An Old Dog - Making Your Truck New Again 1.0

ATS Diesel has teamed-up with X Games Snowmobile Champ Chris Burandt for a retooling of his GM Duramax Truck. With the current price of new diesels and low trade-in value offered by dealers, Chris decided to go a different route rather than buy new; Teach an old dog some new tricks.
[Guest post by Chris Burandt]:

The day is almost here!  On Oct 17 my truck goes under the knife under the careful hands of the crew over at ATS Diesel Performance.  It's time to take the 'ole dualler up a couple notches.  Make that a bunch of notches!  Compound turbos, Twin CP3's, head studs, EFI Live tuned by ATS, Cognito 4" lift, Fox Shocks, Fusion bumpers front and rear, Rigid Lighting, N-Fab steps and a wrap from Fineline graphics.  That should do the trick!

This crazy project all started when a buddy of mine brought over his new Duramax and we went for a test drive.  After riding in the very quiet, super smooth and pretty decent powered stock truck I got the new truck itch.  (That new car smell gets me every time!)  So down to the dealer I went with my super clean 04 Duramax which just cracked 170,000 miles.  Just got er' broke in the way I like.

Now I know I haven't bought a new truck in a while but holy crap have things got expensive.  This is where things started to get a little eye opening for me.  The truck I was looking at replacing my sweet ride with ended up being over $61,000!  Yeah that first number is a 6!  So I took a pretty big gulp and said, "Ok, so how much will you give me for my truck?"  Now I'm thinking even though it's got some miles on it, I'm super anal about my truck and it get's washed more than my 2 year old son does.  So that should be worth something right?  When the salesman told me he could give me $12,000

I thought to myself, "Is he just trying to buy the tranny, turbo and sweet exhaust brake off of my truck for $12,000?"  Nope, $12,000 for the whole shoot-n-match.  So let me get this straight, this guy wants my perfectly good truck and $49,000 for this shiny new thing sitting in front of me that has half the power of my rig and has none of the fun stuff that we all do to all of our vehicles.  Say what!?!  Let's just say that didn't make much sense to me.  So I jumped back in ole white and headed down the road.

This got me thinking, why not take a fraction of the money I was going to have to pony up to buy a new stock truck and just make my perfectly good dirtymax new to me!  Thus, all of the goodies above.  Stay tuned as through out the build I'll be posting some pictures and updates of how the transformation is going.  Can you say TWINS Basil!!!!  (If you haven't seen Austin Powers that last line won't make much sense to you.  But if you have, you've got a smile on your face just like me!)

Stay tuned!
-Chris Burandt

Metal Shop Fummins Truck Giveaway Night

Friday night the Metal Shop Build concluded (for the most-part) at a party thrown by KBPI Radio at Quaker Steak. A big crowd of key winners and others who just wanted to get in on the action headed to Westminster CO. to check out the truck in the parking lot before one person would finally have their key start the engine and take possession of their prize.

Coyote Motorsports Arrives With
The Raptor 700 Prize

By 7pm the parking lot was overflowing as KBPI awarded the final set of ignition keys. Coyote Motorsports rolled in with a new Raptor 700 quad to add to the prize package. Each key was placed inside it's own tiny envelope and hung on a pegboard in front of the fummins truck. One-by-one the key recipients stepped up to the truck to try their luck. One or more of the contestants, as noted by the night's host - Willie B., had traveled from a few states away to try to win the truck.

Some time later and with some frozen Bud Light Girls desperately looking-on Dominic H. and his wife Adrianna finally handed Willie the winning key. Everyone knew that a winner had finally stepped forward; Not by the sound of engine starting, but rather by the screaming coming out of Adrianna.
As the deadline arrived for the giveaway night there were still some loose ends with the build that ATS, Master Craft, and Car Toys will be working on now in order to hand over truck to Dominic. Thanks to everyone that took part in this year's Metal Shop and congratulations to Dominic and Adrianna!

<<< Check out the flash player below for the rest of the photos. If your flash player is not up-to-date visit http://www.flash.com >>>

Metal Shop Fummins Final Hours

The final trim pieces are painted and coming together on the truck. Yesterday the guys were finishing with some work to the brakes and finishing fabrication with the suspension system. The truck is looking pretty complete with all of the body pieces being added where they belong.

Front Grill is ready complements of Camaros Plus

 A couple of finishing details will have to be added after the giveaway tonight due to the hours involved in building the main parts of truck. After ATS the Fummins will go to Car Toys for the sound system and then onto Master Craft Auto for the interior and upholstery work.
The person who finds out that they have the winning key to the truck tonight at Quaker Steak and Lube will definitely be taking possession of a one-of-a-kind vehicle. There will be a lot of potential to modify the truck for more performance in the future and we're hoping that the truck will show back up for more upgrades and updates.

Metal Shop Fummins Truck Glass, Electrical, And Wheels

Bill's Englewood Driveshaft Helps Out On The Driveline

High Class Auto
Glass Installs
The Windows

As the guys were working on getting the driveline in-place thanks to Bill's Englewood Driveshaft, the boys from High Class Autoglass stopped by to get new glass put in the Fummins Metal Shop Truck. The windows were tinted which matches the black paint scheme nicely.

While this was happening the guys from ATS had the intercooler propped-up in front of the engine while the charge air pipes were fabricated and fitted. On the back of the truck the custom dual battery tray was mounted for the Optima's, which will help keep the engine compartment clean and more open.

Zach and Nelson got more work done to the engine compartment and have been running electrical and fitting pieces for the engine and the dash. The custom dash will have updated gauges from Autometer and should give the truck's interior a great look.

Wheels From Jazz It Up

New wheels and tires arrived from Jazz It Up to match the black body pieces and are being fitted on the front and rear. The bumpers and body trim pieces are being coated in the same black as the main body and will be bolted on once the major work is done to the other areas.

Zach had some modification to do on the back of truck and spent last night welding the supports for the 4-Link Suspension System.

Red Top Optima's In Custom Bracket	Intercooler Is Prepped For Install
Sizing-Up The Door	Engine Work & Cab Fitment
High Class Preps New Windshield	Zach Fabricates Intercooler Pipes
Where am I?	Nelson Works On Electrical
You Can't	Doug and Zach Fabricate The Custom Dash
Mike Brings In The New Wheel Set	Camaros Plus Preps The Trim Pieces
Chris Modifies The Front Suspension For New Wheels	Zach Welds Part Of The 4-Link Suspension